Wall Plank

ABSTRACT

A wall plank includes a body portion, a tongue located along a first edge, a groove located along a second edge, and a decorative film. The decorative film is disposed over the body portion and the tongue. The decorative film is unbroken as the decorative film extends over the body portion and the tongue.

BACKGROUND

To alter the appearance of walls, decorative paneling is sometimes added. This paneling may be sheets of wood and wallpaper. When the sheets of wood are installed, additional trim pieces are needed to cover the fasteners used to attach them to a wall. The sheets of wood can be expensive for the consumer and may require special tools to install.

SUMMARY

Presently disclosed are wall planks In some embodiments, the wall planks include a body portion, a tongue located along a first edge, a groove located along a second edge, and a decorative film. The decorative film is disposed over the body portion and the tongue. The decorative film is unbroken as the decorative film extends over the body portion and the tongue.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this Summary intended to be used to limit the claimed subject matter's scope.

DESCRIPTION OF THE FIGURES

Non-limiting and non-exhaustive embodiments are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

FIG. 1 shows a wall system; and

FIG. 2 shows wall planks of the wall system of FIG. 1.

FIG. 3 shows the wall planks of FIG. 2 in isolation.

FIG. 4 shows an enlarged view of a portion of the wall planks of FIG. 3.

DETAILED DESCRIPTION

Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific embodiments of the invention. However, embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Therefore, the following detailed description is not to be taken in a limiting sense.

The present application discloses wall planks and a method for installing the wall planks The main structure of the wall planks may be constructed of compressed wood products and plastics. The main structure of the wall planks includes a body portion, a tongue and a groove. A decorative film may be applied to the main structure of the wall planks The decorative film may be continuous (i.e., unbroken) as it covers the main structure.

Turning now to the figures, FIG. 1 shows a wall system 100. The wall system 100 includes a plurality of studs 102. A sub-material 104 may be attached to the plurality of studs 102. Examples of the sub-material 104 include, but are not limited to, a gypsum material such as DRYWALL®, a concrete backer board, and a wood material such as plywood.

As described below with respect to FIG. 2, a plurality of wall planks 106 may be attached to the sub-material 104 and the plurality of studs 102. The wall system 100 may or may not include the sub-material 104. For example, the sub-material 104 may be omitted and the plurality of wall planks 106 may be attached directly to the plurality of studs 102.

FIGS. 2-4 show the attachment of the plurality of wall planks 106 in greater detail. Each of the plurality of wall planks 106 includes a body portion 202 having a tongue 204 located along a first edge and a groove 206 located along a second edge. The plurality of wall planks 106 may be made primarily of compressed particle board, a polymer, and a cement material. For example, the body portion 202, tongue 204, and groove 206 may be made of compressed wood chips held together with an adhesive matrix. In addition, the body portion 202, tongue 204, and groove 206 may be made of a polymer and concrete material (e.g., for an exterior use).

A decorative film 208 disposed over the body portion 202 and the tongue 204 such that the decorative film 208 conforms to the shape of the wall plank 106. Consequently, application of the decorative film 208 does not significantly change the shape of the wall plank 106. The decorative film 208 may be unbroken as the decorative film 208 covers the body portion 202 and the tongue 204.

In example embodiments, the decorative film 208 covers the body portion 202 and the tongue 204, but does not extend to cover an entirety of a back portion 203 of the wall plank 106, since the back portion 203 of the wall plant 106 is not typically visible in use. In other examples, an entirety of the wall plank 106 can be covered by the decorative film 208, except the edges of the wall plant 106.

For example, the decorative film 208 may begin at point 210 and cover an outward portion (i.e., projecting from wall system 100) of the wall plank 106, the tongue 204, and a portion of the groove 206. Other configurations are possible. In some embodiments, the decorative film 208 has a decorative pattern for aesthetic effect. For example, the decorative film 208 can have a wood grain pattern for aesthetic effect. In another example, the decorative film 208 can have a printed water ripple pattern for aesthetic effect.

The plurality of wall planks 106 may include a ledge portion 214 located adjacent the body portion 202 and the tongue 204. The ledge portion 214 may have a size sufficient to allow a nail 216 to pass through it. The ledge portion 214 may have a size sufficient to allow the nail 216 to pass through substantially normal to the tongue 204. By allowing the nail 216 to pass through the ledge portion 214, a special angled nail gun may not be needed. In addition, the ledge 214 supports the tongue 204 such that during installation, a risk of damage to the tongue 204 may be minimized. For instance, an installer may be less likely to break the tongue 204 off of the body portion 202 with a hammer strike because a portion of the tongue is supported by the ledge 214.

The groove 206 may include a first lip 218 and a second lip 220. The second lip 220 may be shorter than the first lip 218. As shown in FIG. 2, the shorter second lip 220 may allow groove 206 to completely cover tongue 204 without interference from the ledge portion 214.

As shown in FIGS. 1 and 2, the plurality of wall planks 106 can be installed by causing a first plurality of fasteners (e.g., the nails 216) to penetrate the tongue 204 of wall planks 106, sub-material 104, and studs 102. The tongue 204 of a first wall plank 106 is covered with the groove 206 of a second wall plank 106. The second and subsequent wall planks 106 are attached in a similar matter as the first wall plank 106. As described above, the plurality of fasteners may penetrate the ledge portion 214 in substantially normal to the tongue 204 of the wall plank 106.

The wall plank 106 may be manufactured in a variety of manners. For example, square stock material may be passed through routing stations where routers may cut away material to form tongue 204 and groove 206. In addition, the wall plank 106 may include contoured surfaces 222 that may be cut by routers and may provide decoration. The contoured surfaces 222 may be beveled (as shown in FIG. 2) and curved.

Furthermore, each of the contoured surfaces 222 need not be the same. For instance, one of the contoured surfaces may be curved and the other may be beveled. The wall plank 106 may also be molded pieces. For example, a mixture of wood chips and a binding matrix may be placed in a mold. Pressure and heat may then be applied to cure the binding matrix and fix the shape of the wall plank 106.

Once the wall plank 106 has been formed, the decorative film 208 is applied to the wall plank 106. The decorative film 208 can be applied to the wall plank 106 in various ways. For example, the decorative film 208 can be wound around a playout reel. As the wall plank 106 pass through an industrial machine, the decorative film 208 plays off from the playout reel. The industrial machine applies the decorative film 208 over the wall plank 106. The industrial machine comprises rollers or pads that press the decorative film 208 down tightly over the wall plank 106 such that the decorative film 208 conforms to the shape of the wall plank 106. An adhesive on the back surface (i.e., the surface facing the wall plank 106) of the decorative film 208 fastens the decorative film 208 to the wall plank 106. In some embodiments, the adhesive is on the back surface of the decorative film 208 while the decorative film 208 is on the playout reel.

In other embodiments, the industrial machine adds the adhesive to the back surface of the decorative film 208 after the decorative film 208 plays off the playout reel. In this example, the decorative film 208 can already have a decorative pattern while the decorative film 208 is wound around the playout reel. Furthermore, in some instances, the playout reel can have enough of the decorative film 208 for multiple wall planks 106.

Reference may be made throughout this specification to “one embodiment,” “an embodiment,” “embodiments,” “an aspect,” or “aspects” meaning that a particular described feature, structure, or characteristic may be included in at least one embodiment of the present invention. Thus, usage of such phrases may refer to more than just one embodiment or aspect. In addition, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments or aspects. Furthermore, reference to a single item may mean a single item or a plurality of items, just as reference to a plurality of items may mean a single item. Moreover, use of the term “and” when incorporated into a list is intended to imply that all the elements of the list, a single item of the list, or any combination of items in the list has been contemplated.

One skilled in the relevant art may recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, resources, materials, etc. In other instances, well known structures, resources, or operations have not been shown or described in detail merely to avoid obscuring aspects of the invention.

While example embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise configuration and resources described above. Various modifications, changes, and variations apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems of the present invention disclosed herein without departing from the scope of the claimed invention.

The above specification, examples, and data provide a description of the manufacture, operation and use of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. 

What is claimed is:
 1. A wall plank comprising: a body portion including a tongue located along a first edge and a groove located along a second edge; and a decorative film disposed over the body portion and the tongue, the decorative film being unbroken as the decorative film extends over the body portion and the tongue.
 2. The wall plank of claim 1, further comprising a ledge portion located adjacent the body portion and the tongue.
 3. The wall plank of claim 2, wherein the ledge portion has a size sufficient to allow a nail to pass through the ledge portion.
 4. The wall plank of claim 2, wherein the ledge portion has a size sufficient to allow a nail to pass through substantially normal to the tongue.
 5. The wall plank of claim 1, wherein the groove comprises a first lip and a second lip, the second lip being shorter than the first lip.
 6. The wall plank of claim 1, wherein the body portion is made primarily of compressed particle board.
 7. The wall plank of claim 1, wherein the decorative film is made of plastic.
 8. The wall plank of claim 1, wherein the decorative film simulates natural wood grain.
 9. A wall plank system comprising: a first wall plank comprising: a first body portion including a first tongue located along a first edge of the first body portion and a first groove located along a second edge of the first body portion, and a first decorative film disposed over the first body portion and the first tongue, the first decorative film being unbroken as the first decorative film extends over the first body portion and the first tongue; and a second wall plank comprising: a second body portion a second tongue located along a first edge of the second body portion and a second groove located along a second edge of the second body portion, and a second decorative film disposed over the second body portion and the second tongue, the second decorative film being unbroken as the second decorative film extends over the second body portion and the second tongue, the first tongue being located in the second groove when the first wall plank and the second wall plank are attached to a wall.
 10. The wall plank system of claim 9, wherein the first tongue further comprises a first ledge portion located adjacent the first body portion and the first tongue, the second tongue further comprising a second ledge portion located adjacent the second body portion and the second tongue.
 11. The wall plank system of claim 10, wherein the first ledge portion has a size sufficient to allow a first nail to pass through the first ledge portion, the second ledge portion has a size sufficient to allow a second nail to pass through the second ledge portion
 12. The wall plank system of claim 10, wherein the first ledge portion has a size sufficient to allow a first nail to pass through substantially normal to the first tongue, the second ledge portion has a size sufficient to allow a second nail to pass through substantially normal to the second tongue.
 13. The wall plank system of claim 9, wherein the first body portion and the second body portion are made primarily of compressed particle board.
 14. The wall plank system of claim 9, wherein the first decorative film and the second decorative film are made of plastic.
 15. The wall plank system of claim 9, wherein the first decorative film and the second decorative film simulate natural wood grain.
 16. The wall plank system of claim 9, wherein the first tongue further comprises a first ledge portion located adjacent the first body portion and the first tongue, wherein the second groove comprises a first lip and a second lip, the second lip being shorter than the first lip, wherein the second lip being shorter than the first lip comprises the second lip being sized to allow the first ledge portion to be located under the first lip when the first wall plank and the second wall plank are attached to a wall.
 17. A method for installing wall planks, the method comprising: causing a first plurality of fasteners to penetrate a tongue of a first wall plank and a wall, the first wall plank including the tongue, a body portion, and a decorative film disposed over the first wall plank and the tongue of the first wall plank, the decorative film being unbroken, except for breaks caused by the first plurality of fasteners, as the decorative film extends over the body portion and the tongue of the first wall plank; covering the tongue of the first wall plank with a groove of a second wall plank; and causing a second plurality of fasteners to penetrate a tongue of the second wall plank and the wall, the second wall plank including the tongue, a body portion, and a decorative film disposed over the second wall plank and the tongue of the second wall plank, the decorative film being unbroken, except for breaks caused by the second plurality of fasteners, as it extends over the body portion and the tongue of the second wall plank.
 18. The method of claim 17, causing the first plurality of fasteners to penetrate the tongue of the first wall plank comprises causing the first plurality of fasteners to penetrate a ledge portion adjacent to the tongue of the first wall plank.
 19. The method of claim 18, wherein causing the first plurality of fasteners to penetrate the ledge portion adjacent to the tongue of the first wall plank comprises causing the first plurality of fasteners to pass through the ledge portion substantially normal to the tongue of the first wall plank.
 20. The method of claim 17, wherein causing the first plurality of fasteners to penetrate the tongue of the first wall plank comprises causing the first plurality of fasteners to pass through the ledge portion substantially normal to the tongue of the first wall plank; and wherein covering the tongue of the first wall plank with the groove of the second wall plank comprises covering an outward facing portion of the tongue of the first wall plank with a first lip of the groove and covering a first portion of a rearward facing portion of the tongue of the first wall plank with a second lip of the groove. 